Control device



Jan. 14, 1941. A. K. FOULDS. 2,22s,515

'CONTROL DEVICE Filed Dec. 16 1936 INVENTOR Patented Jan. 14, 1941 UNITED STATES PATENT OFFICE CONTROL DEVICE Applieation December 16, 1936, Serial N0. 116,085

16 Claims.

My invention relates generally to control systems and more partlcularly to control systems for fuel stokers of heating system-s.

One o! the objects of my invention is to pro- 5 vlde a new and improved control system for confor controlling operation ofan electric motor,

and having novel means for controlling the heat;

motor to determine the time interval of operation of the electric motor.

Another object of my invention is to provlde a thermostat having a temperature responsive means for controlling the circuit o f a motr and One which will intermittently make and break the circuit; of the motor when the temperature of the temperature responsive means is above a. predetermined temperature.

Another object, of my Invention is to provide a.

- control devlce of the above-mentioned chara.oter

which will be eflicient in opration and yet one which will be Inexpensive to manufacture.

The invention conslsts in the improved con struction and combination ofparts, to be more fully descri-bed hereinafter and the novelty of which will be particularly pointed out and distinctly claimed.

In the accompanying drawing, to be taken as a part 015 this speclflcation, I have fully and clearly illustgrated my invention, In which drawing Flgure 1 is a. diagrammatic view of a controlsystem embodying my invention, and

F1g. 2 is an enlarged view showing certain details of construction of 'my improved thermostat and taken along the line 22 of Fig. 1.

Referring I;o the drawing by characters of reference the numeral I designates in general a motor, preferably an electric mot'or which, among other uses, may be employed to drive a fuel stoker (not sho'wn') of a heating apparatus. The motqr I 'is connected by lead wires 2 and 3 to ma.in lead wires 4 and 5 respectively, which may lead from the usual 110V line. The main 1ead wires l and 5 lead to a transformer II having the usual primary coil I and secondary coil 8, the main lead wires being cohnected eo the transformer primary I in the usual manner.

My control device, designated in general-bythe numeral9, is connected in circuit withthe transforxner se'condary 8 and controls the opexation of,

the x'notor I. The control device 9 may be Iocated cor'1tacts.

in a room or other enclosed space, the temperature or condition of the air of which is to be controlled, and the control device may include a. supporting member or base I0 on which there may be mounted a. suitable element I I responsive to the condition of the ambient air. In the present instance the condition responsive element II is a thermostatic or bimetallic blade. The blade I I may be secured adjacent One end thereof to and adjacent the lower end of the base I0, and extending upward preferably has its upper er free end positloned for movement between two spaced, substantially aligned contact members I2 and I3. The contact members I2, I3 are preferably screws, adjustably screw threaded into supporting members or brackets I4 that may be rigidly secured Iso the ba-se I0, which base is preferably formed of a good electric Insulating material. Carried or supported by euch of the brackets' M below the contact members I2, I3 there is a magnet I5 preferably of the so-called permanent bar type, these magnets prefer-ably being arranged with their positive poles in spaced 0pposed relation and disposed toward opposite sldes of the blade II. The magnets I5 move blade II with a snap actlon when the blade moves within the range of efiective attractive force of one 'or the other of the magnets, and serve to hold the b1a.de in positlve engagement; with one or the other'of ehe contact members I2, I3 to prevent sparking at the The blade I I is connected by a lea.d Wire I6 to the transformer secondary 8 and the contact member I2 is also connected to the 'transf'ormer secondary by a lead wire II. A relay I8 controls the circuit of the motor I and in turn is sontrolled by the thermostat. The relay I8 may be of the conventlonal type having a core I9 surrounded by a coil and having a movable armature 2I serving as a switch. The coil 20 is cannected in the thermostat lead wire I II and the II becomes dissatisfied, that is, calls for heac or' for other changes in the air of a room, the blade II will malte contact wlth the contact me'mber I2 which will close the circuit of th relay I8 causing switch 2I to close the circuit of the motor I. The motor I will then operate until such time as the blade;ll is again satisfied, or

until the desired condltion of the air of a room ture 01 the heating fiuid from becoming t0o 10W. In my thermostat, when the blacie II is satlsfied or is heated t0 a predetermined temperature, iI: will engage contact member I3 closing the circuit 01 the relay I8 which in turn will close the circuit of the motor I. T0 prevent undue or excessive supply of heat a room or other enclosed space when the thermostatic blade I I is satisfied anal engages contact member I3, I provide for I:he motor I to be operated at relatively short filme intervals as compared to the time interval of operation of the motor when blade I I engages contact member I2, and to this end I employ a heat motor 23 for periodically moving blade II out of engagement with contact I3 to thereby periodically open the circuit of the motor I.

'Ihe heat motor 23 may be mounted on the thermostat base I0 below the contact member I3, on the opposite side of the blade II from the contaci: member I2. The heat motor includes a casing 26 that is preferably of elongated form arranged with one end disposed toward the blade II, and this casing is also preferably formed of a good heat and electric insulating material. The casing 28 has an internal wall 21 that preierably extends substantially parallel with the casing end walls and divides the interior of the casing into two chambers 28 and 29. 'Ihe chamber 29, which may be termed the outer chamber, preferably has a metallic liner 29 forming a bulb element, and surrounding er wrappe'd around the liner 01' bulb element 29 there is a coil of resistance wire 30 for generating heat. One end of the coil 30 is connected t0 Ishe coutact member I3 by a. lead wlre 3I and a tapped coil intermediate the ends thereof is connected 130 the transformer secondary 8 by lead wire 32 that is shown connected the lead wire I'I. The coil 30 may be so a'rranged that the portion thereof in series circuitwith the contact; I3 be 0f sufilciently 10W resistance and current; carrying capacity that the drop in voltage therehrough is not of sufllcient magnitude I;o prevent operation of the re1ay 20.

Positioned in the other chamber 23, which may be termed the inner cha.mber, there is a pressure responsive means, preferably a metallic bellows member 34. The bellows member 34 is a1- ranged 130 expand and contract longitudinally of the casing 26 and Das its opposite ends closed by and hermetically sealed to movable end walls or plate members 35 and 36 that cooperate with i;he bellows to provide a closed expansible chamber 3T. 'I'he bellows expansible chamber 31 is communicatively connected to the heating coil chamber 29 by a flexible tube o1 conduit 33 that extends through an aperture in the internal wall 21 and has one end hermetically secured and sealed In an aperture in the metallic liner 25. The other end of the conduit 33 is secured in an aperture of and hermetically sealed to the rear end wall or plate 33 02 the bellows member 34 so that the bellows member, conduit 33 und element 29 pr'ovide a sealed enclosure that coutains or is charged with a suitable volatile, expansible-contractible fluid. Within the bellows chamber 23 there is preferably a hellcal coil spring 40 that; surrounds I:he flexible conduit 33 and has one end abutting the internal Wall 21 and the other end abutting the opposed bellows end Wall 3G. 'I'he spring 43 ls under compression and prevents outward movement o1 the bellows end wall 33 ab fluid pressures below a predetermined pressure. In the event that the pressure 015 the fluid in the bellows 34 becomes excessive, as may occur for example in summer, the spring 40 will be overcome und the bellows end wall 36 will be moved outwrd toward wall 21 permitting expansion of chamber 31 to prevent undue increase o! internal fluid pressure which might otherwise rupture the bellows.

Carried by the bellows movable end wall 33 there is a reclprocal thrust member or rod 42 that projects through the end wall 02 the cas- Ing 26 and extends substantially transverse to the blade II, the thrust member 42 also preferably extending between the blade und the base I0, see Fig. 2. The rod 42 extends beyond or past the blade I I and has an end portion that is slidably received and guided in a tubular member 43 that may be secured to the thermostat base I0. Adjustably screw threaded into the outer end of the tubular member 43 there is a thumb screw 44 the lnner end 015 which serves as an abutment; for the rod 42 to limit movement of the rod upon expansion of the bellows 34. After I;he end 015 rod 42 engages the stop screw 44 there is provision for lost motion and further expansion of the bellows 34 may be had through movement of the bellows end wall 33 against spring 40, providlng that; the force exerted by the thermostatic fluid is sufllcient to overcome the spring. The thxust rod 42 1s formed out 01 square stock, in the present Instance, the member 42 having a square shank 43 that is slidably received and guidec l In an aperture in the inner end wall o1 casing 23. Externally of I;he casing 23 the shank 45 has a portion 01 reduced perimeter, as at 43, and formed out of the reduced portion 43 and facing toward abutment 44, as seen in Fix. 1, there Is a V-shaped portion 41 having a knife edge 43 disposed toward und i'or engaglng the opposed side of the blade II. When the thrust; rod 42 Is moved outward by expanslon of the bellows 34 the knite edge 43 will, after predetermined autward movement 015 the rod, engage and move the blade II to break contact between Ishe blade and contact member I3, bat the stop screw 44 is arranged I:o limit outward movement 02 the rod 42 to prevent blade II from being moved lnto engagement with the other contact member I2.

In order control I:he operation o1 the heat motor 23 so that when the thermostatic blade II is dissatisfled the motor I will operate for relatively short I:Ime Intervals, and will be cutout for relatively long time intervals, I provIde for having a portion o! the resistance coil 33 energized when Ishe motor I Is cut-out to thereby prolong the cooling-down perlod ot the heat motor.- This portion 02 the resistance coil Is prelerably of such resistance that when the transformer voltage 1s impressed directiy across the resistance portion, the heat generated thereby is of less magnit ucle than that generated by the portion in serles with contact; I3 and relay I3. T0 this end the coil 33 may be connected to the transformer secondary 3 by a. lead wire 50 which in the drawing, Is shown oonnected to the lead w1re I3, the resistance coil 33 thus Wing in shunt or parallel circuit with the therrnostatic blade II.

T0 determine 0x select I;he I:Ime period 02 operation of the motor I und I.he cut-out time period, a. rheostat 5I may be provided for varying or selecting the desired coil portion I:o be energized during the cut-out period o! the motor I. 'Ihe rheostat 3I may be-o! any suitable type and as in I:he present lnstancle. may be mounted 0x secured to the underside of the heat motor casing 26. The rheostat 5I may include a conductor member in the form of a sllde bar 52 to which the lead wire 50 may be connected, and the slide bar may be rigldly secured to the casing 26 by screws, or by other sultable means.

The slide bar 52 may be spaced. from the casing 26 by tubular spacer members 53 thrdugh which the screws may extend and screw thread into the casing. Secured to the underslde of the casing 26, in relative spaced relation, there may be a plurallty cf contact r terminal members 54, and slidably supported on the slide bar 52 there may be a manually operable contact member 55 for cooperatlon wlth the contact memhers 54. Each 01 the contacts 54 may be connected by a wire 56, or other current conducting means, to the resistance coil 30, the wlres 56 being connected to the coil 30 at spaced intervals along lts length. It will now be apparent that by means of the rheostat I adesired portion of the coil 30 may be energized to generate predetermlned heat for heatlng the thermostatlc fluid. I1 the rheostat 5I is set so that more heat is generated by the coil 30 on the 01T phase of motor I, the time perlod between engagement and disengagement of the blade II and contact member I3 will be reduced and the time period of cooling-down of the heat motor 23, to permlt engagement between the blade II and contact I3, will be lncreased.

In order that the shunt circuit ot the coil 30 will be closed only on disengagement of the blade II and eontact I3, I provide a. switch 51 in the lead wire 50 and operate the swltch by the heat motor 23, The swltch 51 may comprlse a pivot.l switch arm 58 and a contact member 59 whlch may be mounted 011 the base III below the thrust rod 42. The pivotal swltch arm 58 may extend longitudinally of the swltch blade and an upper end portion thereof may be positioned for abutment by theoutwardly faclng shoulder, as at 60, provlded between the shank 45 end the reduced portion 46 of rod 42. The upper end portion of the swltch arm 58 is bent or rounded so as to provlde a convex surface for engaging the shoulder 80 to reduce frlction between the parts. AI: its lower end the swltch arm 58 ca.rries a contact member GI for cooperation with the contact member 59, the latter coutact member prefera.bly being a screw adjustably screw threaded into a supportlng member or bracket 82 that may be rlgidly secured to the base I0. The swltch arm 58 and lts cooperating: contact member 59 are arranged such that as the thrust rod 42 moves outwa.rd to break contact between blade II end contact member I3, the swltch arm'58 ls pivoted in a dlrection to make contact with contact member 59.

The operation of the herein described vsystem in connection' with controlllng the operatlon of a stoker ls as follows: When the thermostatlc former se'condary 8. Additional heat will now be supplied by operation of the stoker to the room 0r other enclosed space to be hea'ted and when the thermostat blade becomes satlsfled lt will disengage from contact member I2 to stop the further supply of heat by opening the circuit of end stopplng the motor I. The thermostatic blade I I will then engage contact member I3 which will energlze the relay I8 and complete the circuit to the motor I through the resistance coil 30, current fiowing from the transformer secondary 8 via lead wire II, lead wire 32, resistance coil 30, leacl wire 3I, contact member I3, blade II, relay I8 and lead wire I8 back to the transformer secondary 8. The reslsta'nce coil 30 will then generate heat which will drive volatiliz'ed fluld into the bellows 34 and expand the bellows, moving thrust rod 42 outwardly. Upon predetermlned outwardmovement of the thrust rod 42 it will engage and move blade II out of engagement With contact I3 opening the circult of the motor I. Movement of the blade II into engagement with contact I2 by the heat motor 23 is prevented by the stop member 44. Movement of the blade II out of engagement with the contact member I3 opens the circult at this point to the resistance coil 30, but outward movement of the thrust member 42 also closes switch 51 which closes a circuit through a portion of the coil 30, the length of the coil employed, and therefore the heat generated, being determined by the rheostat setting. After the blade I I has been moved out cf engagement with the contact mem ber I3 lt is held out of engagement w1th the cantact I3 for a period of time because of the heat holdover of 1;he thermostatic fluid, which holdover ls enhanced by the heat insulatlng casing 28. As the thermostatic fluld of the heat motor cools, the bellows 34 will contract, -moving rod 42 Which will permit blade II to again contact the contact member I3 and Start motor I providing, of Course, that the blade I I is still satisfied to the extent that it will follow the retracting rod and move through the necessary distance to engage the contax:t member I3. Also, as the thrust rod 42 is retracted, the swltch arm 58 Will bep r mitted 170 pivot by gravity out of engagernent with its cooperative contact member 59, opening the shunt circult of the resistance coil 30. I t will thus be seen that the blade II, when satisfled, Will close the circuit of motor I for a relatively short time period and that the heat motor 23, under the control of blade II, will perlodically open the circult of motor I for relatively long time perlods.

While I have herein described my control de.- vii:e in connection with a heating system, lt is to be understood that my device is adapted for use in a.ny system in which under certain conditlons lt is desired to operate a motor for relatively long time intervals and under certain other conditlons to operate the motor for relatively short tlme perlods.

As prevlously mentioned, the switch 51 controlllng the shunt circuit of the resistance coil 30 will provide for a savingof electrical energy because wheir the blade I I is cooperatlng with the conta.ct I 2, the switch 51 will be open ancl the reslstance coil 30 will be completely deenergized, or will not be generating any hea.t. During the t'1me perlod When the blalde II is dissatlsfied, that ls, When lt is cooperatlng with comtact I2, the heat motor 23 will cool down to, or

approach the temperature cf the amblent air, with the result that when the blade agaln becomes dlssatisfied and cooperates with contact I3, the initlal heating-up period '0f the heat m0tor will be longer than subsequent heatlngmp periods, but obviously thi s condltion i's not; o1 a serious natura. However, thls condition may be obviated, if desired, by connecting the resistance coil 30 to the transformer secondary 8 so that; a. portion 0f the coil will be energized during the period when the blade II is dissatisfied. Or in other words a portion of the resistance coi1 30 may be at all times in closed circuit with the transformer secondary 8 and this arrangement will, of course, eliminate the switch 5'I. But as pointed out above, if the switch 51 is eliminated additional current will be used in operating the heat motor '23.

The device I herein referred to as a motor may, within the scope of my invention, be any electrically energized or actuated means such, for example as a power means or a Signal (either audible or visual) What I cla.im and desire 130 secure by Letters Patent of the United Stabes is:

l. In a control system, a heat motor for comtro1ling an elz'zctric circuit be made and broken, means operable automatically and couizrolling energization of said heat mo cor, and heater means rendered operable upon deenergization of said motor for increasing the time period during which the circuit will be open.

2. In a control system for controlling the oper ation of an electrically operated means switch means operable to control the electrically operated means, a periodically ene;gized heat motor cooperable with said switch means to control che electrically operated means, and means for determining solely the time period of cooling of the herat motor thereby 110 determine the time period of deenergization of the electrically operated means.

3. A control for a, heating system having e1ectrically operated means controlling supply 01' heat to an enclosed space, an electrically operated heat motor, a thermostatic b1ade operable when the temperature of the enclosed space reaches a predet'ermined temperature to close the circuit of the electrically operated means and the circuit of the heat motor, said heat motor being operable t0 move said blade to open the circuit of the electrically operated means and ehe circuit of said heat; motor, and heating means for heating said heat; motor upon deenergization 015 said heat motor thereby to pro-- long the rate of cooling of said heat motor so as to cut-out the electrically operated means for a relatively long time interval.

4. A control for controlling the circuit cf an electrically operated means comprising, means responsive a fluid characteristic and operable to control said circuit, a temperature responslve means for controlling said circuit, one 0f said controlling means being operable to close said circuit and the other of said controlling means being operable 1:0 open said circuit, a heating means for said temperature responsive means, and a. second heating means i'm said temperature responsive means said seconcI-named beating means being energized upon deenergization of said first-named. heating means thereby to prolong I:he cooling of said temperature responsive means when said circuit is open so that said circuit Will be open for a relatively long time period.

5. A control for controlling the circuit of an electrically operated means comprising, means responsive a. fluid characteristic ai1d operable thereby to control said. circuit, a. heat motor including a temperature responsive element operable to move said responsive means to control sa.id circuit, one of said controlling means being 1 operable to close said circuit und the other o! said oontrolllng mea.ns beim: operable to open said cir'cuit, an electrica.lly energized hea.ting means for heating sald temperature responsive element and operable upon deenergization of said heat motor thereby to prolong the cooling of said temperature responslve element, and a rheostat cooperable with sald heating means for varying the rate of cooling of sa1d temperature responsive means.

6. A control for controlling the circuit 015 an electrically oprated means comprising, means responsive to a fluid characteristic and operable thereby to control sa.1d clrcuit. a. heat motor including a. temperature responsive element operable to move said responsive means to contro1 said circuit, one of sa.id controlling means being operable to close said circuit und the other of said controlling mea.ns beim; operable 1:0 open said circuit, a. hea.ting means for heating sa1d temperature responsive element and operable upon deenergization o1 sa.id hea.t motor thereby to prolong the cooling 015 saicl temperature responsive element, and heat insulating means enclosing said temperature responsive element und sald heating mea.ns.

7. A control system comprlsing a. movable condition responsive means, a. controlled device. sai d device being energized on movement o! said responsive means in one direction, said dev1ce being energized on movement of said responslve means in the opposite direction, power means energized an movement 015 sald responsive means in said opposite direction, sald power means acting upon energization to move said responsive means to deenergize sa.id controlled device and said power means.

8. A control system comprising a. movable condition responsive means, a. controlled device, said device being energized on movement of said responsive means in one direction, said device being energized on movement o1 said responsive means in the opposite direction, power means energized on movement 015 sa1d responsive means in said opposite direction, sa.id power means acting upon energization to move said. responsive means in said one direction to deenergize said controlled device und sa.l'd power means, and means to stop the movement of said responsive means by said power means short of reenergization of sa.id controlled dev1ce.

9. A control systexn comprising a movable coudition responsive means, a controlled device, sa.1d device being energized on movement of said responsive means In one direction, said device being energized 011 movement of said responsive means in the opposite direction, a. heat responsive power means, means to transmit movement Irom said power means -to s&id responslve means, means to supply hea.t to said power means, and means conflning the heat supplied to said power means to control the cooling 01 said power means upon decrease of heat supply 120 said power means, operation of said responsive means in sa1d opposite direction actuating sa.id heating means to supply hea.t to said power means, said power means acting upon predetermined heat input by said supply means to move said responsive means to deenergize said controlled dev1ce and to decrea.sta the supply of heat by said beating means, said controlled devlce being reenergized by movement of seid responsive means in said opposite dlrection upon predetermined cooling of said power means.

10. A control system comprislng a movable condition responsive means, a controlled device. said device being energized on movement; of said responsive means in one direction, said device being energized on movement of said responsive means in the opposite direction, a heat responsive power means, means to transmit movement from said power means to said responsive means, means to supply heat; to said power means, means coufinlng the heat supplied t;o said power means to control the cooling of said power means upon decrease of heat supply to said power means, operatlon of said responsive means in said opposite direction actua.ting said heating means to supply heat to said power means, said power means acting upon predetermined heat input by said supply means to move said responsive means to deenergize said controlled devioe and decrease the supply of heat by said heating means said controlled device being reenergized by movement of said responsive means in said opposite dlrection upon predetermined cooling of said power means, und means controlling the time period of cooling of said power means.

11. A control system for controlling the operation 015 a fuel stoker for a heating apparatus comprlsing a contact member, a thermostatic element responsive to the temperature cf a. space to be heated and cooperable with said contact member control operation of the stoker, said element when satisfied engaging said contact member to increase the fuel input by said fuel stoke r by an amount suflicient to maintain combustion, a heat motor energized by engagement of said contact member by said element; and operable to move said element out of engagement with said contact member to decrease the fuel input of the stoker, and means for determining the time period of cooli ng of said heat motor so tha.t said elemenfi und. said contact member will be in engagement for a. predetermined relatively short J:ime period and will be out of engagement for a predetermined relatively lang time perlod.

12. A control system for controlling the operation of a, fuel stoker of a heating apparatus comprising a contact member, a thermostatic element: responsive to the temperature of a space to be heated and cooperable with said contact member to control operatlon of said stoker, said element when dissatisfled moving in one direction und engaging said conta.ct member to increase the fuel input by the sboker by an amount sufflcient to maintain combustion, a second contact member, said element when satisfied moving in the opposite direction and engaglng said secondnamed contact member to increase the fuel input by the stoker by an amount sufflcient to maintaln combustion, a heat motor energized by engagement o1 said element with said second-named contact member and operable to move said element out of engagernent with said second-named conta.ct member, and heatlng means for determining the time period of cooling of said heat motor so that said element will be in engagement w1th said second-namcd contact member for a. predetermined relatively short time period and will be out of engagement wlth said secondnamed. contact member for a predetermined relat1vely 1ong time period.

13. A oontrol system for controlling the oper ation of a. fuel stoker of a heating apparatus comprising a contact member, a, thermostatic element responsive to the temperature of a space to be heated and cooperable with said contact member to control' operation of said stoker, said element when dissatisfied moving in one direction and. engaging said contact; member to inc rease the fuel lnput by the stoker by an amount suflicient to maintain combustion, a second contat member, said element when satisfied moving in the opposite direction and engaging said secondnamed contact member to increase the fuel input by the stoker by an amount suflcient to maintain combustion, a heat motor energized by engagement of said element with said secondnamed contact member and operable to move said element out of engagement with said secondnamed contact member, heating means for determining the time period of cooling of said heat motor so that said element will be in engagement With said second-named contact member for a predetermined relatively short time period anal will be out of engagement with said secondnamed contact member for a predetermined relatively 1ong time period, and stop means for limiting movement of said element by said heat; motor to prevent movement of said element by said heat motor into engagernent with said first-named contact; member.

14. A control for controlling the circuit of an electrically operated means comprising, means responsive to a fluid characteristic for controlling said circuit, a. heat motor controlled by said circuit und operable to control said responsive means, an electrical resistance means for hea.ting

said motor, a pbrtion of said resistance meatns being in said circuit and operable to actuate the heat motor upon the cl0sing of said circuit by said responsive means, means operable to energize a second portion of said resistance means to prolong -the cooling of said hea.t motor upon -1 movement cf said responsive means by said heat motor .to open said circuit.

15. In a. control ystem, energizable means, re-

- sponslve means for controlling said means and periodic movement a.nd actlng periodica.lly to energize said energizable means during .the time said responsive means is away from said actlve position.

16. In a control system, an elect rically operated controlling means, means responsive to a. fluid characterlstic and operable to control the circuit of said controlling means, a heat motor coutrolling said circuit, an electrical resistance means having -two portions operable to heat said motor, said resistance means having one of said portions energized upon operation of said responsive means to deenergize said controlling means circuit, said one portio n acting when energized to heat said heat motor to control said circuit, said resistance means having the other of said porti0ns etfective .to prolong ehe cooling of said heat motor and the deenergization of said c0ntrolling means a.nd energized by the circuit controlling operation of said hea.t motqr.

ANDREW K. FOULDS. 

